designing and analysis of cng tank and frame structure ...(iso11439) (33) operating conditions of...

International Journal of Technical Innovation in Modern

Engineering & Science (IJTIMES) Impact Factor: 3.45 (SJIF-2015), e-ISSN: 2455-2585

Volume 4, Issue 4, April-2018

IJTIMES-2018@All rights reserved 257

Designing and Analysis of CNG Tank and Frame Structure for Two-

Wheeler SI Engine

Shivam M Pandya1, Dipak C Gosai2

1Mechanical Department &Shri S’ad Vidya Mandal Institute of Technology, Email id: [email protected]

2 Mechanical department & Shri S’ad Vidya Mandal Institute of Technology, Email id: [email protected]

Abstract- Government of India’s philosophy of going green to reduce emission levels, in cities there is a thrust to

increase the gas distribution network. With an increase in naturel gas (CNG) vehicles. However, in last few year there are

so many gas operated vehicle in automobile industry, manly it consist four wheeler, auto, bus, etc. but very few in two

wheeler. It is one type of research gap in two-wheeler. Looking to Indian scenario population is increasing and economy

the number of two-wheeler user also increasing very broadly, compare to any other wheeler. Which are major issue to

increasing emission, which harm the environment. There for it is required to reduce exhaust emission and economic

vehicle operation.

To adopt CNG vehicle for current used, it is required new innovative design of gas storage tank, especially for

two-wheeler. It also required to investigate enough space and proper location of storage tank for conventional vehicle. In

this research, work doing on designing gas tank for two-wheeler with respect to safety aspects. And also protect to gas

tank, we used trellis frame structure, which adequate space and safety with batter performance. The modelling is done on

SOLID EDGE, and analysis done on ANSYS 16 software.

Keywords –CNG Gas Tank, Frame Structure, Two-wheeler, CNG Bike, alternate fuel .

I. INTRODUCTION

Air pollution refers to the contamination of the earth's environment with constituents that have considerable effects

on human health. The quality of life or the natural environment gets affected when pollutants accumulate in the air

at higher concentrations [1]. Vehicles emissions have become the fore most source of air pollutants including carbon

monoxide, lead, nitrogen dioxide, sulphur dioxide, ozone and particulate matters [2]. Vehicles emission mainly from

automobiles is responsible for about two third of air pollution in the urban area. Vehicles emission mainly from

automobiles is responsible for about two third of air pollution in the urban area. Petrol engines exhaust contains high

concentration of HC whereas the diesel vehicular exhaust has higher concentration of particulate matter, NOx and

CO2. The concentration of CO and unburnt HC in the diesel exhaust are slightly lower as compared to petrol engine

[3]. The increase in the number of vehicles can be taken as a measure of the economic development of the Indian

automotive industry. About 7-8 million vehicles are produced annually in the country today [4]. In 2004 country had

reported 72.72 million registered vehicles whereas in 2013 it increased to 182.45 million, so the registered motor

vehicles has almost more than doubled in last 10 years as is also shown in detail in Table 1 [5]. Motors Vehicles are

the primary source of air pollution in India’s major cities. Two-third (66%) pollutants are reported to be released

from vehicles in Delhi alone, 52% in Bombay and close to one-third (33%) in Calcutta. The transportation sector in

India consumes about 17% of total energy and responsible for 60% production of the greenhouse gases emission

from various activities [4].

International Journal of Technical Innovation in Modern Engineering & Science (IJTIMES) Volume 4, Issue 04, April-2018, e-ISSN: 2455-2584,Impact Factor: 3.45 (SJIF-2015)


Categories Co2 Co Nox SO PM HC

g/km/year

Bus 28748.16 207.26 679.73 79.24 31.36 51.72

Omni Buses 8508.42 60.94 200.53 23.45 9.28 15.11

2-Wheeler 8701.08 719.64 62.15 4.25 16.36 464.49

LMV(Passenger) 4378.10 370.29 92.93 2.11 14.52 10.16

LMV(Goods) 44654.58 442.04 110.94 123.02 17.33 12.13

Cars and Jeep 23901.22 212.30 22.14 5.67 3.22 38.01

Taxi 2367.08 10.23 5.68 117.05 .80 1.48

Others 5705.22 57.41 64.54 32.19 3.98 8.96

Emission from different vehicles as reported in India [4]

A. Importence of two wheeler in india –

Now days in India population is increasing day by day, and number of auto vehicle user are also increasing.

The two-wheeler is most popular vehicle to get to work in India. According to ice 2016 survey the chart table shows

the different automobile vehicle user in various locations. It also shows, two-wheeler user is very huge compare to

other vehicle in various locations. [10].

.

Chart Table Shows Different Vehicle Work with Various Location [30]

The large fleet share and rapid growth of two vehicles in India means that careful attention must be paid to

reducing emissions and fuel consumption from these vehicles. As per the Society of Indian Automobile

Manufacturers (SIAM) is the apex Industry body representing leading vehicle and vehicular engine manufacturers in

India. Bellow chart shows two-wheeler operators are more and sailing of two-wheeler is increasing 12.26% in

previous year 2016 as per SIAM source.

B. Designing a frame structer –

Among all this frame, best suitable frame for our resource is trellis frame, due to its tubular structure and high

strength.

Figure 1. Trelis frame and model



Specification Overall length: 1300mm

Overall width: 397mm

Material: aluminum alloy, composite material

Día of tubular pipe: 30mm

Thickness: 4mm

Weight:6.871kg

Overall Height:1165

Wheelbase: 1350

Ground Clearance: 150

Seat Height:790mm

Material Selection

Sl No Material Young’s

modulus E Gpa

Possion’s

ratio

Density

Kg/m3

Yield stress

Mpa

Ultimate tensile

stress Mpa

1 Steel 210 0.3 7850 350 490

2 Aluminium

alloy 6063 68.9 0.33 2700 214 241

3 Carbon fibre 73.1 0.33 2780 324 469

4 Titanium 119 0.34 4430 880 900

Material property [23]

Boundary Conditions

The rear end portion and portion of handle in front is made fixed (as shown in figure 4 by whitish portion) and then

various loads are applied and the analysis was done.

Load Conditions Applied

Rider Weight=70kg

Pillion Weight=70 kg

Fuel Tank Weight=20 kg

Engine Weight=40 kg

Total load = 2000N

Stress analysis

Steel

Stress Analysis Deformation Analysis

Aluminium Alloy 6063



Result comparison

Sl no Material Max. stress in Mpa Max displacement in mm Weight in kg

1 Steel 20.35 0.1426 19.991

2 Aluminium Alloy 6063 20.51 0.431 6.8751

3 Carbon fibre 20.51 0.410 7.079

4 Titanium 20.558 0.252 11.281

Stress Vs Displacement

Validation

From results of finite element analysis of chassis, it is observed that stresses are maximum at joint locations. It is

also observed that all the materials have stress values less than their respective permissible yield stress values. So,

the design is safe. [23]

Among this material, aluminium alloy 6063 is best suitable material for our frame structure, because it has similar

stress and displacement with least weight compare to others material.

Impact Test on Frame Structure At 8000N

0

5

10

15

20

25

weight displacement stress

Result

steel Aluminium Alloy 6063 Carbon fibre Titanium



Impact test results

Direction Deformation (mm) Stress (Mpa)

Front 0.76012 78.866

Right and left 1.606 224.98

To increasing impact strength of frame, provided a many truss and cross member is designed to sustain various types

of load. For front impact load, cross member is attached to frame, which Is more safety provided to tank, and it is

shows in fig.

Designing gas tank

The innermost layer is made of High density polyethylene (HDPE) and is called Liner. The properties of HDPE are

given below in the Table 1 (Zhang (2009)).

Material Property of HDPE Liner (34, 35)

Density (g/cm3) Tensile Strength (Mpa) Elastic Modulus (Gpa) Poisson’s ratio

0.92-0.95 10-16 69.2 0.499

The mechanical properties of glass/epoxy and carbon/epoxy laminated composite board used as the outer

reinforcement layers are depicted in Table.2

Mechanical properties of glass/epoxy laminated composite board

Property Unidirectional Glass/Epoxy

In-plane longitudinal modulus (GPa) 20.6

In-plane transverse modulus (GPa) 17.2

In-plane shear modulus(GPa) 17.3

In-plane Poisson's ratio 0.117

Out-of-plane Poisson's ratio 0.112

Out-of-plane Poisson's ratio 0.114

Longitudinal tensile strength (MPa) 380

Transverse tensile strength(MPa) 334

Load and Boundary Conditions

Tests were performed at three different pressures i.e. operating pressure of 20 MPa, water test pressure of 30 MPa

and design bursting pressure of 73 MPa (Table 3) and hoop constraint is applied at the end of the cylinder.

(ISO11439) (33)

Operating conditions of all-composite gas cylinder (Yue and Li (2012), ISO 11439) (33,34).

Operating temperature Operating pressure Filled medium Water test pressure Design bursting pressure

-40 0C to 60

0C 20Mpa Natural gas 30 Mpa 73 Mpa

Design (cylinder)



Operating Pressure of 20 Mpa

Stress distribution Deformation

Similarly find the stress and deformation at 30Mpa and 70Mpa

Dimensions of Designed tank

Overall length: 460.14mm

Width: 171.54mm

inner volume: 4.19e-12

mm3

Thickness: 7.5mm+9mm+9mm

Layer: 3 layers HDPE+ epoxy(helical) +epoxy(hoop)

surface volume: 4.2181e+006 mm³

weight (without gas): 6.29

gas capacity 600grm apox

Remaining volume in frame structure 43.33e06

mm3

Running km 108km

Analytical Calculation of Principal Stress and Max Shear Stress (36)

Pressure ( Mpa ) Strain at different direction ɛ µ Strain value ( 𝒎𝒎

𝒎𝒎 )

20

X 0.001173

Y 0.001416

Z 0.002012

30

X 0.001885

Y 0.002108

Z 0.002526

73

X 0.00321

Y 0.00412

Z 0.00361

For 20Mpa, ɛx = 0.001273, ɛy = 0.001396, ɛz = 0.002012

ýxy = 2ɛy- ɛx- ɛz

ýxy = 2(0.001396) – (0.001273) – (0.002012)

= -493 µ

Principal Stress

σx=𝐸

1− 𝜈2 (ɛx + 𝜈ɛy)

σx =69.2 ∗109

1−(0.4992 ) [0.001173+ (0.499 0.001416)]

σx =165.65Mpa

σy=𝐸

1− 𝜈2 (ɛy + 𝜈ɛx)

σy =69.2 ∗109

1−(0.4992 ) [0.001416+ (0.499 0.001173)]

σy =184.32Mpa



Max shear stress

τmax = σ𝑥− 𝜎𝑧

2 or τmax =

𝑝𝑟

2𝑡

where, p – is internal pressure(mpa)

r – inner radius of cylinder (mm)

t – thickness (mm)

τmax = 20∗42

2∗7.5 = 56Mpa

Now, similarly find for another pressure

Principal Stress and Shear Stress at 30Mpa

σx =187.32Mpa

σy =241.65Mpa

τmax= 84Mpa

principal stress and shear stress at 73Mpa

σx =483.35Mpa

σy =524.67Mpa

τmax= 204.4Mpa

Result comparison

Pressure (Mpa) FEM Analysis Analytical

Maximum

Principal Stress

(Mpa)

20 101.81 165.65

30 153.34 187.32

73 374.93 483.35

Maximum Shear

Stress (Mpa)

20 53.606 56

30 80.98 84

73 198.76 204.4

Assembly of Frame Structure and CNG Gas Tank

Important Specification

Fuel capacity 3liter petrol + 1.2 kg CNG gas

Over all weight 98.67 kg

Average 70km/ liter petrol and 90km / kg CNG

Total running kilometre 290km at full condition



CNG Bike Layout (Management)

Final Compression

Hero splender CNG motorcycle

DIMENSION CNG BIKE

Length 1970mm 1870 mm

Width 720 mm 467 mm

Height 1040 mm 1020 mm

Saddle height 785 mm 700 mm

Wheelbase 1230 mm 1320

Ground clearance 159 mm 210 mm

Fuel tank capacity 11 litres petrol Gas:2.9kg and petrol: 3 litres

Kerb weight 110 kg 107.26kg

Max payload 130 kg 130 kg

Chassis type Tubular double cradle type Trellis

Tyre Size Front 2.75 x 18 - 42 P / 4 PR 2.75 x 18 - 42 P / 4 PR

Tyre Size Rear 2.75 x 18 - 48 P / 6 PR 2.75 x 18 - 48 P / 6 PR

Service cost

Cost 43,000/- 63000/-



Over All Mass Calculating

Petrol tank weight CNG tank weight total = 13.39 kg

Empty tank = 4.6 kg Empty petrol tank mass = 600 gram

Fuel mass = density * volume Fuel Mass = 0.77 kg/ litter * 3 litter

= 0.77kg/ litter * 12 litter = 2.91 = 3 Kg

= 9.24 kg Pressure Reducer Weight = 2kg

Total fuel tank weight = 13.84 kg Total Fuel Tank Mass = 13.39kg + 3kg

Frame weight =11.98kg =16.39kg

Frame Wight = 6.8kg

Total mass of petrol bike 110 kg Total mass of CNG bike 107.26kg

IV.CONCLUSION

In the present study of design, a frame structure for cng gas tank in two-wheeler, results are discussing bellow.

Structural analysis trellis frame has been done on by using four materials viz. steel, aluminium alloy 6063,

carbon fibre and titanium. The maximum stress values are coming out to be 20.35 MPa, 20.51 MPa, 20.51 MPa,

20.55 MPa respectively. From the results it is observed that the stresses are maximum at joint locations and also for

all the materials the stress values are less than their permissible yield stress values. So, the design is safe. By using

aluminium alloy 6063 as the material has less density compared to other materials used and is also cheap in cost, this

is the best suited alternate material for the chassis and is expected to perform better with satisfying amount of weight

reduction. Impact stress analysis also done on frame structure, for safety of gas tank from impact loading. this

impact test result is shows the strength of frame structure at deferent load condition. This strength is increased due to

number of truss member are attached.

Designing a composite pressure vessel by utilize optimum space available in frame structure. Result of

Stress analysis on various pressure condition, working pressure, test pressure and hydraulic burst. The maximum

stress values are coming out to be 101.81 MPa, 153.34 MPa, 374.93 MPa, respectively. From result we observed

that all the von miss stress is less than the allowable stress, so designed is safe. Correlation between the analytical

prediction and numerical simulation result are presented and discussed. The analytical max principal stress and shear

stress is calculated and compare with FEM model which are similar.

The manufacturing of CNG motorcycle by using of aluminum 6063 alloy trellis frame with CNG tank, so that safety

of gas tank increased and motorcycle weight is similar to petrol bike.

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